Senior Failure Analysis & Epoxy Engineer

Position: Senior Failure Analysis & Epoxy Engineer

Position Summary

The Senior Failure Analysis & Epoxy Engineer is responsible for conducting comprehensive failure investigations to determine the root causes of product and process issues arising from manufacturing operations and customer returns (RMA). The position provides technical expertise in failure-analysis methodologies, material characterization, and electronic assembly materials, including epoxy, solder, PCB/PCBA construction, and related materials.

The role collaborates closely with Manufacturing, Process Engineering, Product Engineering, Quality, R&D, and customer-facing teams to identify failure mechanisms, recommend corrective actions, and improve product reliability and manufacturing quality.

Key Responsibilities

• Lead failure-analysis investigations for manufacturing issues, product failures, and customer RMA cases.

• Determine failure mechanisms and identify root causes using structured problem-solving and analytical techniques.

• Serve as a technical expert in failure-analysis methods, laboratory techniques, and material characterization.

• Perform analysis on electronic manufacturing materials, including epoxy, solder, adhesives, coatings, and PCB/PCBA construction materials.

• Conduct material characterization and analytical testing to support product design, process development, material selection, and qualification.

• Operate and interpret results from analytical equipment, including FTIR, SEM/EDX, X-ray, TGA, and DSC.

• Prepare samples using cross-sectioning, polishing, and lapping techniques for microscopic inspection and analysis.

• Apply basic electrical fault-isolation techniques to support the investigation of electrical and electronic failures.

• Analyze technical data and correlate analytical findings with product design, materials, processes, and failure symptoms.

• Prepare comprehensive failure-analysis reports and technical presentations that clearly communicate findings, evidence, root causes, and recommendations.

• Work with cross-functional teams to develop corrective and preventive actions and follow through until effective closure.

• Support laboratory equipment, test methods, data-acquisition systems, and automation improvements.

• Maintain accurate laboratory records, test results, and technical documentation.

• Ensure laboratory activities comply with applicable safety, quality, and ISO/IEC 17025 requirements.

• Provide technical guidance and training to engineers, technicians, and other stakeholders on failure-analysis methods and material-related issues.

Qualifications and Experience

• Master’s degree in Materials Engineering, Materials Science, Chemistry, Physics, or a related technical discipline; or a bachelor’s degree with at least five years of relevant hands-on failure-analysis experience in an electronics manufacturing environment.

• At least 5 years of experience conducting failure analysis for electronic products, components, PCBAs, or manufacturing processes.

• Strong hands-on experience with failure-analysis and material-characterization techniques.

• Proficiency in using and interpreting results from FTIR, SEM/EDX, X-ray, TGA, and DSC.

• Practical experience in cross-sectional sample preparation, including cutting, mounting, polishing, and lapping for microscopic inspection.

• Good knowledge of electronic assembly materials and construction, including epoxy, solder, adhesives, coatings, PCB, and PCBA structures.

• Experience in technical data analysis, hardware, software, board design, or automated data-acquisition systems is preferred.

• Basic knowledge of electrical fault-isolation techniques and electronic circuits is an advantage.

• Understanding of laboratory quality-management systems in accordance with ISO/IEC 17025.

• Experience with structured problem-solving tools such as 8D, 5 Why, Fishbone Analysis, FMEA, or DOE is preferred.

• Good written and verbal communication skills in English.

• Ability to communicate technical findings clearly and work effectively with cross-functional and global teams.

Key Competencies

• Strong analytical thinking and systematic problem-solving skills.

• Excellent technical judgment and attention to detail.

• Ability to translate complex analytical findings into clear conclusions and actionable recommendations.

• Strong ownership and commitment to timely results.

• Effective cross-functional collaboration and technical communication.

• Ability to manage multiple failure-analysis cases and priorities.

• Commitment to laboratory safety, data integrity, quality, and continuous improvement.

We are an equal opportunity employer and value diversity at our company.